Parts management system and method of use

ABSTRACT

A parts management system includes a compartment having a plurality of cup-shaped cells formed in the base of the compartment. Side walls of the compartment include notches formed therein. The parts management system further includes dividers that may be engaged with the notches to subdivide the parts management system into smaller subcompartments. In use, smaller parts, such as fasteners, are detached from an item to be disassembled and placed in the cup-shaped cells within particular subcompartments. The larger components associated with the fasteners are removed from the item to be disassembled and are also loaded into the subcompartments in proximity to their associated fasteners. The parts can be loaded into the parts management system in sequential order during disassembly of the item. The parts can then be unloaded from the parts management system in a reverse order during reassembly of the item.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to organizational systems. Morespecifically, the present invention relates to a system for efficientlymanaging parts during disassembly and assembly of an item.

BACKGROUND OF THE INVENTION

Motor vehicles, such as automobiles, trucks, buses, and so forthinevitably require maintenance, repairs, or some other service. Therepair and maintenance of a motor vehicle often requires small parts tobe removed and placed aside for later re-installation. During the repairor servicing, a professional or amateur mechanic must keep track of theparts and components being removed from the motor vehicle so that theymay later be reinstalled onto the motor vehicle. Efficient management ofthe removed parts and reinstallation of those same parts can be dauntingfor the mechanic. This problem may be exacerbated when multiplemechanics are servicing the same vehicle. For example, one mechanic maynot have a clear understanding of where a part or parts were removedfrom the vehicle by another mechanic, and how those parts should bereinstalled. Additionally, during disassembly and reassembly of a motorvehicle, the small parts can be easily misplaced.

In a professional motor vehicle repair or service environment, confusionbetween mechanics, misplaced parts, and mistakes made during automotiveservicing can increase the time to repair or service a vehicle, thussignificantly decreasing the efficiency of an automotive shop.Consequently, a professional mechanic's inefficiency results inincreased costs for the automotive shop, which in turn can result inincreased costs for the consumer.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description and claims when considered inconnection with the Figures, wherein like reference numbers refer tosimilar items throughout the Figures, and:

FIG. 1 shows a perspective view of a parts management system inaccordance with an embodiment;

FIG. 2 shows a top view of the parts management system of FIG. 1;

FIG. 3 shows a side view of the parts management system;

FIG. 4 shows a perspective view of a divider used with the partsmanagement system;

FIG. 5 shows a side view of the divider; and

FIG. 6 shows a partial perspective of the part management system in use.

DETAILED DESCRIPTION

Embodiments entail a parts management system and a method of managingparts using the parts management system. The parts management system canbe used during disassembly and assembly of an item in order to organizeand retain small parts, such as fasteners, together with their largercomponents. The parts management system is implemented in anorganizational process in which parts that are disassembled are loadedin a specific order into the parts management system and cansubsequently be unloaded from the parts management system in the reverseorder for reassembly. Accordingly, reassembly of the item can beperformed by another individual or individuals since those individualscan ascertain from the parts management system where the parts go and inwhat order they are to be reassembled.

Such a parts management system may be useful in an automotive shop whenremoving parts from a motor vehicle in order to repair the motorvehicle. Thus, multiple mechanics with varying degrees of ability andpresent during different work shifts can disassemble and reassemble avehicle or portion of a vehicle with increased efficiency. Increasedefficiency of disassembly, repair, and reassembly can decrease the cycletime, i.e., the amount of time that elapses between the between thebeginning and end of an automotive repair, thereby decreasing cost forautomotive repairs. Furthermore, improved organization of parts can leadto a decrease in misplaced parts and/or a decrease in mistakes madeduring automotive servicing. Although the parts management system andmethodology are discussed below in connection with automotive servicing,it will become readily apparent that the parts management system andassociated methodology may be implemented in a variety of environmentsin which an item having multiple parts is to be disassembled and laterreassembled.

Referring to FIGS. 1-3, FIG. 1 shows a perspective view of a partsmanagement system 20 for managing a plurality of parts in accordancewith an embodiment. FIG. 2 shows a top view of parts management system20, and FIG. 3 shows a side view of parts management system 20. Partsmanagement system 20 generally includes a first compartment 22 and asecond compartment 24 coupled to first compartment 22. In an embodiment,parts management system 20 may be a tray structure formed from athermoplastic material, such as, polyethylene, polypropylene,acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), nylon,and the like. Thus, parts management system 20 including first andsecond compartments 22 and 24, respectively, may be manufacturedutilizing a suitable molding process, such as injection molding, blowmolding, rotational molding, and so forth. A thermoplastic material anda molding technique are desirable for making parts management system 20due to cost effective production, as well as, high durability, corrosionresistance, and light weight of the finished product. In alternativeembodiments, parts management system may be manufactured using othersuitable materials and manufacturing processes.

First compartment 22 includes a first end wall 26, a second end wall 28,a first side wall 30 and a second side wall 32, where first and secondside walls 30 and 32 extend between first and second end walls 26 and28, respectively. A base 34 of first compartment 22 is surrounded byfirst and second end walls 26 and 28, and first and second side walls 30and 32. More particularly, a bottom edge 36 of each successive one offirst end wall 26, first side wall 30, second end wall 28, and secondside wall 32 is coupled to an outer perimeter 38 of base 34. Thus, firstend wall 26, first side wall 30, second end wall 28, and second sidewall 32 extend above an upper surface 40 of base 34.

Base 34 includes a plurality of generally cup-shaped cells 42 extendingbelow upper surface 40, and each of cup-shaped cells 42 has an opening44 formed through upper surface 40. In an embodiment, cup-shaped cells42 may be arranged in multiple rows 46 oriented transverse to a length48 of first compartment 22. In this exemplary configuration, firstcompartment 22 includes thirteen rows 46 of cup-shaped cells 42, witheach row 46 including three of adjacent cup-shaped cells 42 (seeparticularly FIG. 2). However, alternative embodiments of partsmanagement system 20 may include fewer or more cells 42 than that shown,and cells 42 may be arranged differently and/or may be made in differingsizes than that which is shown. As will be discussed below in connectionwith FIG. 6, cup-shaped cells 42 are configured to contain a pluralityof parts separate from one another.

Interior surfaces 50 of first and second end walls 26 and 28, as wellas, interior surfaces 52 of first and second side walls 30 and 32 definefirst compartment 22 having base 34 with cup shaped cells 42. In anembodiment, interior surface 52 of first side wall 30 includes spacedapart notches 54 formed therein. Likewise, interior surface 52 of secondside wall 32 includes spaced apart notches 56 formed therein. One eachof notches 54 formed in first side wall 30 directly opposes one each ofnotches 56 formed in second side wall 32 to form pairs of notches 58.Each pair of notches 58 may be located between adjacent rows 46 ofcup-shaped cells 42.

Parts management system 20 further includes one or more dividers 60.Dividers 60 are configured to slideably engage with pairs of notches 58.That is, one each of dividers 60 may be concurrently slid into one ofnotches 54 formed in first side wall 30 and one of notches 56 in secondside wall 32 such that first compartment 22 is subdivided into two ormore subcompartments 62. Dividers 60 are not shown in FIG. 2 for clarityof illustration. However, in the example shown in FIG. 1, four dividers60 have been engaged in opposing pairs of notches 58 so that firstcompartment 22 is subdivided into five subcompartments 62. As willbecome apparent in the ensuing discussion any suitable quantity ofdividers 60 may be utilized to subdivide first compartment 22 intosubcompartments 62 when organizing parts in parts management system 20.

With continued reference to FIGS. 1-3, second compartment 24 includes athird end wall 64 formed adjacent to first end wall 26 of firstcompartment 22, a fourth end wall 66 formed adjacent to second end wall28, and a third side wall 68 extending between third and fourth endwalls 64 and 66. Third side wall 68 is laterally displaced away fromsecond side wall 32. Thus, second side wall 32, third end wall 64, thirdside wall 68, and fourth end wall 66 surround a base 70 of secondcompartment 24. In an embodiment, base 70 may be substantially planar,as opposed to base 34 of first compartment 22 having cup-shaped cells 42formed therein.

As shown in FIG. 3, first compartment 22 exhibits a first height 72 froma first upper edge 74 of first compartment 22 to a bottom surface 76 ofcup-shaped cells 42. Second compartment 24 exhibits a second height 78from a second upper edge 80 of second compartment 24 to base 70. In anembodiment, first and second heights 72 and 78 are substantially equalfor simplicity of manufacture and to facilitate the stacking of multipleparts management systems 20 together. However, in alternativeembodiments, second height 78 need not be equivalent to first height 72.

Unlike first compartment 22, second compartment 24 may not includecup-shaped cells and/or notches. Instead, second compartment 24extending length 48 of first compartment 22 may be better suited forlarger components that may not fit in subcompartments 62 of firstcompartment 22. Of course, in alternative embodiments second compartment24 may include cup-shaped cells and notches so that compartment 24 mayalso be subdivided into subcompartments 62. And in still otherembodiments, a parts management system 20 may include only firstcompartment 22 without having second compartment 24.

Referring to FIGS. 4-5, FIG. 4 shows a perspective view of one ofdividers 60 that may be used with parts management system 20, and FIG. 5shows a side view of divider 60. The following discussion appliesequally to each of dividers 60 that may be engaged with firstcompartment 22 (FIG. 1). Divider 60 includes a body 82 having a loweredge 84, and upper edge 86, and side edges 88 and 90, respectively.Lower edge 84 is configured for abutment with upper surface 40 (FIG. 1)of base 34 (FIG. 1), and side edges 88 and 90 are configured forengagement with notes 54 and 56 (FIG. 1) of any of pair of notches 58(FIG. 1).

A rigid flap 92 may be fixed to upper edge 86 of body 82. In anembodiment, rigid flap 92 may be bent out of alignment with body 82 ofdivider 60. For example, rigid flap 92 may be bent downwardly so thatwhen engaged with pair of notches 58 (FIG. 1), rigid flap 92 is directeddownwardly toward base 34 (FIG. 1) of first compartment 22. Divider 60may be formed from a metal, such as aluminum. Thus, rigid flap 92 can bereadily bent into the appropriate shape. Alternatively, divider 60 maybe suitably manufactured from another material, such as a thermoplasticmaterial. The bent configuration of rigid flap 92 provides a handhold sothat a user may readily slide divider 60 into or out of pair of notches58. Additionally, rigid flap 92 may provide a useful surface upon whicha user may write labels identifying the particular parts stored in oneof subcompartments 62 (FIG. 1). For example, when divider 60 ismanufactured from a slick, non-porous material, a non-permanent markermay be used to temporarily label rigid flap 92. Later, the erasable inkmay be removed from rigid flap 92 so that divider 60 can be re-used.

FIG. 6 shows a partial perspective of parts management system 20 in usewhen disassembling and reassembling parts from an item. In an exemplaryscenario, the parts are to be removed from a motor vehicle 94, which isshown in dashed line form for illustrative purposes. For example, amechanic may remove a door panel so as to repair body damage, to replacea malfunctioning component in the door panel, and so forth. Removal of adoor panel can entail the disassembly of a plurality of parts. Theseparts can include smaller parts, such as fasteners 96, and theassociated components 98 that are connected to motor vehicle 94 viafasteners 96.

In general, a method by which parts management system 20 may be used tomanage or organize a plurality of parts entails detaching the smallerparts, e.g. fasteners 96, that retain a particular component 98 ontomotor vehicle 94 so that component 98 is removed from motor vehicle.Fasteners 96 are placed in cup-shaped cells 42 in first compartment 22of parts management system 20. The mechanic may engage one of dividers60 in a suitable pair of notches 58 in first and second side walls 30and 32, respectively to form one of subcompartments 62. In thisillustration, the mechanic may form a first subcompartment, labeledsubcompartment 62A. Thus, the mechanic loads fasteners 96 into one ormore cup-shaped cells 42 in first subcompartment 62A.

Once fasteners 96 are loaded into cells 42 within first subcompartment62A, the larger part, e.g., component 98, may also be loaded into firstsubcompartment 62A. The mechanic may additionally mark flap 92 ofdivider 60 with one or more identifiers 100 that identify the parts,e.g., fasteners 96 and/or component 98, contained in firstsubcompartment 62A. Preferably, the mechanic or mechanics repeats theoperations of detaching fasteners 96, engaging dividers 60 to formsubcompartments 62, placing fasteners 96 into cells 42 within aparticular one of subcompartments 62, and loading the associatedcomponent 98 into the particular one of subcompartments 62 forsuccessive parts to be removed from motor vehicle 94. Thus, thedisassembled components 98 and their corresponding fasteners 96 areloaded into subcompartments 62 in a sequential order, for example fromfront to back as indicated by an arrow 102.

During reassembly, components 98 can be unloaded from parts managementsystem 20 in the reverse order. That is, the earliest fasteners 96 andcomponents 98 loaded into parts management system 20 are the lastfasteners 96 and components 98 to be unloaded from parts managementsystem 20. Likewise, the last fasteners 96 and components 98 loaded intoparts management system 20 are the earliest fasteners 96 and components98 to be unloaded from parts management system 20. Accordingly, thisdisassembly methodology enables the parts from a disassembled item,e.g., a portion of motor vehicle 94, to be organized in a way thatanother individual or individuals who may be reassembling the item knowswhat parts go where and in what sequential order the item is to bereassembled.

Components 98 are loaded into the appropriate one of subcompartments 62,e.g., first subcompartment 62, when the subcompartment 62 is sized toaccommodate component 98. That is, dividers 60 may be engaged with pairof notches 58 to create an adequately sized subcompartment 62. Onoccasion, however, the component may be too large to fit into itscorresponding subcompartment 62. In such a situation, the component maybe loaded into second compartment 24. By way of example, a secondcomponent 104 is placed in second compartment 24. However, itscorresponding fasteners 96 are placed in cup-shaped cells 42 of the nextsuccessive subcompartment 62, e.g., a second subcompartment 62B. Ofcourse, additional smaller parts (not shown) associated with secondcomponent 104 may be placed in second subcompartment 62B, as well.Divider 60 used to form second subcompartment 62B may be suitably markedwith identifiers that identify fasteners 96 in second subcompartment 62Band that identify second component 104 loaded into second compartment24.

Embodiments described herein entail a parts management system and amethod of managing parts using the parts management system. The partsmanagement system can be used during disassembly and assembly of an itemin order to organize and retain small parts, such as fasteners, togetherwith their larger components. That is, subcompartments can bedynamically formed and appropriately sized using dividers that engagewith notches formed in side walls of the system. The subcompartmentsinclude cup-shaped cells in which the smaller parts, such as fasteners,can be placed while the larger components associated with the fastenerscan also be loaded into the same subcompartment. Thus, the partsmanagement system is implemented in an organizational process in whichparts that are disassembled are loaded in a specific order into theparts management system and can subsequently be unloaded from the partsmanagement system in the reverse order for reassembly. Consequently,reassembly of the item can be performed by another individual orindividuals since those individuals can ascertain from the partsmanagement system where the parts go and in what order they are to bereassembled. Such a parts management system and organizational processenables multiple users with varying degrees of ability and variousspecialties and/or working on different work shifts to disassemble andreassemble an item with increased efficiency. Increased efficiency ofdisassembly and reassembly can decrease the cycle time of the process,thereby decreasing costs. Furthermore, improved organization of partscan lead to a decrease in misplaced parts and/or a decrease in mistakesmade during disassembly and reassembly.

Although the preferred embodiments of the invention have beenillustrated and described in detail, it will be readily apparent tothose skilled in the art that various modifications may be made thereinwithout departing from the spirit of the invention or from the scope ofthe appended claims. For example, the parts management system can beconfigured in various shapes and sizes, and can have fewer than or morethan the quantity of compartments and the quantity and arrangement ofcup-shaped cells shown in the presented figures.

What is claimed is:
 1. A system for managing a plurality of partscomprising: a first end wall; a second end wall; a first side wall; asecond side wall, said first and second side walls extending betweensaid first and second end walls; and a base surrounded by said first andsecond end walls and said first and second side walls, said baseincluding a plurality of generally cup-shaped cells configured tocontain said plurality of parts separate from one another.
 2. A systemas claimed in claim 1 wherein said base includes an upper surface andsaid cup-shaped cells extend below said upper surface.
 3. A system asclaimed in claim 2 wherein each of said cells has an opening formedthrough said upper surface of said base.
 4. A system as claimed in claim2 wherein a bottom edge of each successive one of said first end wall,said first side wall, said second end wall, and said second side wallare coupled to an outer perimeter of said upper surface of said basesuch that said first end wall, said first side wall, said second endwall, and said second side wall extend above said upper surface of saidbase.
 5. A system as claimed in claim 1 wherein said first and secondend walls and said first and second side walls define a firstcompartment having said base with said plurality of cup-shaped cellsformed therein, and said system further comprises a second compartmentadjacent to and extending a length of said second side wall.
 6. A systemas claimed in claim 5 wherein said second compartment comprises: a thirdend wall formed adjacent to said first end wall; a fourth end wallformed adjacent to said second end wall; a third side wall extendingbetween said third and fourth end walls and laterally displaced awayfrom said second side wall; and a substantially planar base surroundedby said second side wall, said third end wall, said third side wall, andsaid fourth end wall.
 7. A system as claimed in claim 6 wherein saidfirst compartment exhibits a first height from a first upper edge ofsaid first compartment to a bottom surface of said cup-shaped cells, andsaid second compartment exhibits a second height from a second upperedge of said second compartment to said substantially planar base, saidsecond height being substantially equivalent to said first height.
 8. Asystem as claimed in claim 1 wherein: interior surfaces of said firstand second side walls and said first and second end walls define acompartment having said base with said plurality of cup-shaped cells,said interior surfaces of said first and second side walls havingnotches formed therein; and said system further includes at least onedivider engaged with said notches in each of said first and second sidewalls and extending between said first and second side walls such thatsaid compartment is subdivided into at least two subcompartments.
 9. Asystem as claimed in claim 8 wherein one of said notches on said firstside wall directly opposes one of said notches on said second side wallto form a pair of said notches for engagement with said at least onedivider, said pair of said notches being located between adjacent rowsof said cup-shaped cells.
 10. A system as claimed in claim 8 whereinsaid at least one divider comprises: a body having a lower edge, anupper edge, and side edges, said lower edge being configured forabutment with an upper surface of said base, and said side edges beingengaged with said notches; and a rigid flap fixed to said upper edge andbent out of alignment with said body.
 11. A system as claimed in claim10 wherein said rigid flap is bent downwardly toward said base.
 12. Amethod of managing a plurality of parts using a parts management system,said parts management system including a compartment, said compartmentincluding a base surrounded by first and second end walls and first andsecond side walls extending above an upper surface of said base, saidbase including a plurality of generally cup-shaped cells extending belowsaid upper surface of said base, and said method comprises: detachingsmaller ones of said plurality of parts from an item being disassembled;removing larger ones of said plurality of parts associated with saidsmaller parts from said item; placing said smaller parts into saidcup-shaped cells; and loading said larger parts associated with saidsmaller parts into said parts management system in proximity to saidsmaller parts.
 13. A method as claimed in claim 12 wherein: said partsmanagement system further includes a divider configured to engage withnotches formed in interior surfaces of said first and second side walls;said smaller parts are fasteners, said larger parts are componentsconnected to said item via said fasteners; said removing operationcomprises disconnecting said fasteners from one of said components andremoving said one of said components; said method further comprisesengaging said divider in a pair of said notches in said first and secondside walls so that said divider extends between said first and secondside walls to form a subcompartment in said compartment; said placingoperation comprises placing said fasteners in at least one of said cellslocated in said subcompartment of said compartment; and when saidsubcompartment is sized to accommodate said one of said components, saidloading operation comprises loading said one of said components intosaid subcompartment.
 14. A method as claimed in claim 13 furthercomprising repeating said detaching, removing, engaging, placing, andloading operations for successive parts to be removed from said item.15. A method as claimed in claim 13 wherein said compartment is a firstcompartment, and said part management system further includes a secondcompartment formed adjacent to said first compartment, and said methodfurther comprises loading said one of said components in said secondcompartment when said subcompartment is too small to accommodate saidone of said components.
 16. A method as claimed in claim 13 wherein saiddivider includes a body and a rigid flap, said body having a lower edge,an upper edge, and side edges, said lower edge abutting an upper surfaceof said base when said divider is engaged in said notches, and saidrigid flap being fixed to said upper edge and bent out of alignment withsaid body, and said method further comprises marking said rigid flapwith identifiers that identify said one of said components and saidfasteners.
 17. A system for managing a plurality of parts comprising: afirst compartment including a first end wall, a second end wall, a firstside wall, a second side wall, and a base wherein said first and secondside walls extend between said first and second end walls and said baseis surrounded by said first and second end walls and said first andsecond side walls, said base includes an upper surface and a pluralityof generally cup-shaped cells extending below said upper surface, andsaid cells are configured to contain said plurality of parts separatefrom one another; and a second compartment coupled to and extending thelength of said second side wall.
 18. A system as claimed in claim 17wherein a bottom edge of each successive one of said first end wall,said first side wall, said second end wall, and said second side wallare coupled to an outer perimeter of said upper surface of said basesuch that said first end wall, said first side wall, said second endwall, and said second side wall extend above said upper surface of saidbase, and each of said cells has an opening formed through said uppersurface of said base.
 19. A system as claimed in claim 17 wherein:interior surfaces of said first and second side walls have notchesformed therein; and said system further includes at least one dividerengaged with said notches in each of said first and second side wallsand extending between said first and second side walls such that saidcompartment is subdivided into at least two subcompartments.
 20. Asystem as claimed in claim 19 wherein said at least one dividercomprises: a body having a lower edge, an upper edge, and side edges,said lower edge being configured for abutment with said upper surface ofsaid base, and said side edges being engaged with said notches; and arigid flap fixed to said upper edge and bent out of alignment with saidbody.